2010 DOE Hydrogen Program Review
Advanced PEM Based
Hydrogen Home Refueling Appliance
(SBIR Phase I)
Michael Pien, Ph.D.
Principal Investigator
ElectroChem, Inc.
Woburn, MA 01801
June 7, 2010
Project ID#
PD064
This presentation does not contain any proprietary, confidential, or otherwise restricted information
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ElectroChem Inc.
OverView
Barriers
Timeline
• Barriers addressed
• Start July 2009
• End January 2010
• 100% Complete
Electrolyzer Based Home
Refueling System for
Passenger Vehicles:
– Feasibility Analysis
– Safety Analysis and Codes
– Projected Costs of system and
product hydrogen
Budget
• Total project funding
– DOE share = $100,000
– Contractor share = none
Partners
• Project lead
ElectroChem, Inc.
• Funding received in FY09 =
100%
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ElectroChem Inc.
Objectives - Relevance
• Develop Simplified PEM electrolyzer appliance design
that supports high efficiency and safe operation at a
scale suitable for home refueling of passenger fuel cell
vehicles.
• Determine technical feasibility, physical operating
parameters, expected reliability and suitability for home
use.
• Determine safety requirements and applicable codes.
• Analyze unit manufactured cost, reliability, operating and
maintenance cost and total costs.
• Examine market impact and acceptability.
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ElectroChem Inc.
Hydrogen Refueling @ Home - Relevance
• Fuels Hydrogen Vehicle Market
“One-Car-At-A-Time”
• Use “Off Peak” Electricity for
low cost H2 fuel @Home
• Safe storage of H2 directly in
vehicle tank
• Convenient to Install and Use
• Solves the “Infrastructure
Challenge”
• Most Rapid Market Expansion
• Lowest Investment Risk
HHR
Unit
•No Operating Manpower Cost
•No Real Estate Cost
•Low Excess Capacity
Provides simplest, cleanest and
most reliable H2 production means.
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ElectroChem Inc.
Plan & Approach
• Feasibility – Define operating requirements based on necessary
performance and customer requirements. (capacity, location, noise,
safety, maintenance.)
• Prelim Design – Specify acceptable designs and detailed
performance specifications. (Power, size, operating schedule, life,
efficiency, feed requirements)
• Design Analysis – Perform bottoms-up and top-down cost analyses
for the production of up to 500,000 units/yr. Identify applicable safety
codes and primary safety factors. Define required maintenance .
• Process Analysis – In a bottoms-up approach, determine complete
hydrogen cost analysis using H2A.
• Technology Development Plan – Identify key technical factors
requiring further development.
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ElectroChem Inc.
Strategic Approach
• Eliminate factors (storage, manpower, real estate) driving high costs
of forecourt H2 fueling systems.
• Design system around typical driver needs.
• Implement the system simplifications allowed by the IFF design.
• Determine all the necessary components in 3 complete versions of a
home refueling electrolyzer system that assume differing technical
advancements over current technology.
• Determine safety factors by comparison with similar solutions
already “codified”.
• Determine bottoms-up cost ,and leverage prior analyses targeting
fuel cell volume manufacturing for vehicle production.
• Compare with competitive electrolyzer system costs via power-rule
scaling.
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ElectroChem Inc.
ElectroChem’s Approach
• The Integrated Flow Field (IFF) allows for a
passive liquid water feed and phase
separation inside each cell. Eliminates
water circulation.
• Radically simplifies system design, lowers
cost, reduces moving parts, and improves
reliability.
• Small size for home refueling allows
simplified direct air cooling of system.
• Can be scaled down efficiently.
• Leverages PEM technology & cost advances
made in fuel cells for vehicles.
O2
H2
-
+
Water
Feed
H2O
H2O
IFF Concept
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ElectroChem Inc.
Accomplishments - Feasibility
• IFF Electrolyzer systems can be
• IFF electrolyzers can be designed
economically scaled to home
to be inherently safe,
refueling capacity if simplified in
environmentally friendly, and
operation and number of moving
suitable for home refueling.
parts.
• Prior ElectroChem market study indicates acceptance of home
refueling if size, cost, reliability, and safety goals can be met.
High
Pressure
H2 Output
Parameter
Hydrogen Production
Capacity
Output Pressure
Period of Operation
Operating Voltage
Daily Commute
Mileage Efficiency of
Vehicle
Annual Mileage
Capacity Utilization
Product Life
Value
1
Units
kg/day
O2
Venting
Pressure
Regulators
Electrolyzer
Stack with
Cooling Fins
Water Condensers
5000
8
240
35
67.5
12,000
50%
10
psi
hrs
Volts (AC)
Miles
Miles per
kg
Miles
AC/DC Converter
& System Controller
Tap
Water
Input
Design
Goals
Cooling
Fan
Water
Reservoirs
1 ft
Years
8
Water
Supply
Pump
DI Water
Cartridge
ElectroChem Inc.
Accomplishments - Prelim Design
• Three Designs Developed
1.
2.
3.
High pressure IFF electrolyzer
Medium pressure IFF Electrolyzer & Compressor
Medium Pressure Conventional Electrolyzer & Compressor
• Electrical supply (6.5 kW) and tap-water (deionized) are
compatible with home use.
• Off Peak (low electricity cost) operation has sufficient
capacity for daily commuting.
• Size (2’ x 2’ x 2’) and noise (45 dB or less) compatible
with home installation outside garage.
• Inherently safe because of direct H2 storage in vehicle.
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ElectroChem Inc.
Accomplishments - Safety Analysis
•
Safety Codes Reviewed
–
–
–
–
•
•
– Similar to CNG Home Dispensing
– Careful design of air venting around
dispensing hose
– Minor Modifications needed for NFPA 52
US national electric and fire codes
SAE vehicle safety standards
ASME process piping standards
International Fuel Gas Code
In-Vehicle storage
•
Electrical Power System
Internal Gas Hazard
– Contained volume is minimized
– Contained flammable gas hazard is small
– Utilizes vehicle safety system
– SAE J2579
•
Compression & Dispensing
•
– Similar to Electric Vehicle system
– Covered by Class 2 EVSE (NEC625)
– Minor Modifications needed for NFPA 52
Installation
– Similar to CNG Home Dispensing
– Minor Modifications needed for NFPA 52
Except for Minor Modifications to Existing Codes
Electrolyzer Based Hydrogen Home Refueler is
compatible with safety standards
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ElectroChem Inc.
Accomplishments –
Bottoms Up System Cost
• Detailed parts cost estimates across all 3 designs
–
–
–
–
–
–
Assume manufacturing volume of 500,000 units/yr.
Utilize state-of-the-art materials usage, & 10 yr life.
Assume stack efficiency of 70%.
Extrapolate component costs from comparable available items
Follow approach used in fuel cell vehicle cost estimations.1
Power Supply costs estimated from Level 2 EV Charging
stations estimates.2
1
E.J. Carlson, P. Kopf, J. Sinha, S. Sriramulu, and Y. Yang, Cost Analysis of PEM Fuel Cell
Systems for Transportation, Subcontract Report NREL/SR-560-39104, December 2005,
Subcontract No. KACX-5-44452-01.
2 Kevin Morrow, Donald Karner, James Francfort, “Plug-in Hybrid Electric Vehicle Charging
Infrastructure Review”, Final Report, Battelle Energy Alliance, Contract No. 58517,
November 2008.
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ElectroChem Inc.
Accomplishments Bottoms Up System Cost
Manufactured Cost – Volume Scaling
Manufactured Cost
Design 1 Design 2 Design 3
$0
$637
$265
$ 614
$265
Cost per unit
Compressor
System
Electrolyzer
System
Power Supply
& Controls
Manufactured
Cost
Relative Cost
$6,000
$736
$471
$ 471
$ 471
$1,108
$1,350
$1,473
1.00
1.22
1.33
Design 1
$4,000
Design 2
Design 3
$3,000
$2,000
$1,000
$0
Total Hardware Cost
Installation
Costs
Total Installed
Cost
Yearly
maintenance
$5,000
100
200
300
400
thousands of units annually
$ 796
$ 796
$ 796
$1,903
$2,145
$ 2,268
$50
$50
$ 50
Conclusions
IFF Designs (1 & 2) are
significantly lower cost
Total Installed Cost is ~$2k
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ElectroChem Inc.
500
Accomplishments
System Cost – Power Rule Scaling
•
Alternative Cost Estimation Method
– Provides a “Reasonableness” check
•
Power Rule Scaling
– Cost-per-unit declines with increased number made
– Cost-per-unit increases less rapidly as unit size increases
– Costs Scale via a simple power law (such as C = K Nα)*
•
Rule applied to Conventional Electrolyzer scaled down to home refueling
size, but increased in number to meet vehicle sales
System Design
Manufactured Cost
Power Rule Scaled - Current Technology
$2,313
Power Rule Scaled - Future Technology
$1,275
IFF High Pressure (Design 1)
$1,108
IFF Med Pressure (Design 2)
$1,350
Conventional Med Pressure (Design 3)
$1,473
Conclusion
Nearly Identical Results
To Bottoms-Up Analysis
* Parameters adapted from cost data on related technologies.
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ElectroChem Inc.
Accomplishments - Process Analysis
• Use Bottoms-Up system costs and estimate H2 fuel
costs via H2A
Key Assumptions
– Utilization 50% (equivalent to 4 hrs/day)
– Off Peak Electricity ($0.055/kW/hr)
– Financing debt at 5%, 10 yr duration
Home Refueling Case
Design 1 – HHR-IFF, No Compressor
Design 2 – HHR-IFF, On-board compressor
Design 3 – HHR Conventional PEM, On-board
compressor
Utilization
50%
100%
50%
100%
50%
100%
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– Construction period = zero
– Land Costs = zero
– Operator Manpower = zero
H2 Fuel
Cost
$4.26
$3.55
$4.39
$3.62
$4.47
$3.66
Electricity
cost %
67%
80%
65%
79%
64%
78%
Annual
Driving
12,000 miles
24,000 miles
12,000 miles
24,000 miles
12,000 miles
24,000 miles
Annual
Fuel Cost
$786
$1311
$810
$1337
$825
$1351
ElectroChem Inc.
Accomplishments - Process Analysis
Cost Sensitivity
– 50% Utilization
– System Design 1
HHR Cost Electrolyzer Sensitivity
Manufactured Cost
($1000 to $2000)
Installation Cost
($500 to $1000)
Electricity Cost
($0.03 to $0.10)
Utilization (100% to
50%)
Appliance Life (20 yr
to 5 yr)
Maintenance Cost
($50 to $200)
$-
$2.00
$4.00
$6.00
$8.00
$/kg of Hydrogen
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ElectroChem Inc.
Accomplishments
Fuel Cell Car Market Impact
• Problem: H2 forecourt stations will be Highly Underutilized during
the first 10 yrs of market growth
• Solution: Home refueling reduces wasted infrastructure by “OneCar-At-A-Time” approach.
• Public Benefit: Home refueling reduces the refueling infrastructure
cost by 50% during the first 10 yrs of market growth. (10 million
vehicles by 2025.)
• Problem: To control cost H2 forecourt stations will be regionally
limited, crippling market growth
• Solution: Home refueling eliminates regional limitations by bringing
fuel to the user.
• Public Benefit: Home Refueling allows market to grow at
maximum rate.
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ElectroChem Inc.
Collaborations
• EPRI supported effort demonstrated
fundamental feasibility of IFF design
• EPRI consultation on current program
(Dan Rastler)
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ElectroChem Inc.
Proposed Future Work
• Demonstrate complete system operation
of IFF based PEM electrolyzer
• Develop membranes for high pressure
PEM electrolysis
• Develop small sized H2 compressors
• Encourage modifications for safety codes
for hydrogen home refueling systems.
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ElectroChem Inc.
Summary
• Home refueling advances hydrogen vehicle market by
solving “Infrastructure Challenge”
• Technologically Integrated Flow Field (IFF) provides the
lowest possible system cost, simplest design, and highest
reliability
• Mass production of low cost system and operation with offpeak electricity provides cost-competitive H2 fuel.
• Electrolyzer appliances are compatible with safe
installation and operation at the home.
• Modest sized units can provide refueling for passenger
vehicles at 5000 psi and higher.
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ElectroChem Inc.
For More Information
Please Contact:
Michael Pien, Ph.D.
Vice President of R&D
Electrochem, Inc.
400 West Cummings Park
Woburn, Massachusetts 01801
Phone: 1.781.938.5300
Fax: 1.781.935.6966
Email: mpien@fuelcell.com
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ElectroChem Inc.
Supplemental Slides.
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ElectroChem Inc.
Accomplishments - Feasibility
Factor
Reformer
Alkaline Electrolyzer
IFF PEM
Electrolyzer
Toxic Chemical
Hazard
Potential for
poisonous CO or
natural gas leakage
Uses Concentrated
Caustic Soda
None
Hydrogen Purity
Requires Purification Requires Purification
Green House
Emissions
Resource Availability
CO2 emitted as
byproduct
None
No Purification
Needed
None
Natural Gas is Not Water and Electricity Water and Electricity
Available Everywhere
is Every Home
is Every Home
Comparison of fundamental characteristics of competing technologies
considered for the HHR appliance. The importance of these factors is that
IFF simplifies the design of a PEM-based HHR. Special considerations for
feed materials, safety of handling, purity of product hydrogen, or
infrastructure needs are not needed.
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ElectroChem Inc.
Accomplishments - Prelim Design
•
Schematic diagram showing the important mechanical system components, excluding sensors
and electrical controls for the high pressure HHR-IFF electrolyzer system. Note that as much
detail as possible is given to ancillary components, since they all contribute to cost.
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ElectroChem Inc.
Accomplishments Prelim Design
•
Schematic diagram showing the important mechanical system components, excluding sensors
and electrical controls for the moderate pressure HHR-IFF electrolyzer system with a
compressor added to reach 5000 psi. Note that as much detail as possible is given to ancillary
components, since they all contribute to cost.
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ElectroChem Inc.
Accomplishments - Prelim Design
•
Schematic diagram showing the important mechanical system components, excluding sensors
and electrical controls for the moderate pressure HHR conventional electrolyzer system with a
compressor added to reach 5000 psi. Note that as much detail as possible is given to ancillary
components, since they all contribute to cost.
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ElectroChem Inc.
Accomplishments - Bottoms Up System Cost
Catalyst
Membrane
Bipolar & Cooling plates
IFF Flow Field
Stack pressure container
Water Resevoir
Heat Exchanger
Catalytic reactor
Gas Cooler, H2 Dryer
Water Supply Pump
DI Water Cartridge
Back Pressure Regulators
Dispensing Hose
Solenoid valves
Cooling Fan
Power Supply & Controls
High Pressure H2
compressor
Buffer tank for mech
compressor
Hi - Pres
Med - Pres
Med - Pres HHR
ElectroChem IFF- ElectroChem IFF- Conv. Electrolyzer
HHR (Design-1) HHR (Design-2)
(Design-3)
$127.00
$127.00
$127.00
$41.90
$41.90
$41.90
$15.04
$15.04
$15.04
$7.52
$7.52
$35.53
$9.21
$9.21
$11.10
$2.88
$8.63
$18.18
$18.18
$18.18
$2.00
$2.00
$2.00
$10.00
$10.00
$10.00
$15.00
$15.00
$15.00
$66.41
$66.41
$66.41
$25.22
$25.22
$25.22
$50.00
$50.00
$50.00
$10.00
$10.00
$25.00
$5.00
$5.00
$5.00
$471.11
$471.11
$471.11
$0.00
$256.47
$256.47
$0.00
$8.63
$8.63
$0.00
$0.00
$24.49
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$73.48
$2.88
$2.88
Hydrogen sensors
$100.00
$100.00
$100.00
System Housing
$44.00
$44.00
$44.00
$52.75
$1,107.76
$64.28
$1,349.85
$70.13
$1,472.66
Water Circulating Pump
Radiator System, Pumps (2),
Thermostat, Valve
H2 Phase Separator
O2 Phase Separator
system assembly cost (5%)
Total System Cost
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Accumulated HHR system
manufacturing cost for the three
designs described above. Note that
the manufactured cost for the IFF
based electrolyzer systems are
substantially lower because several
components are not necessary to its
operation. This makes the
conventional electrolyzer system
33% more expensive that the high
pressure IFF version. The primary
cost difference points are based on
the mechanical compressor and the
forced water cooling system.
ElectroChem Inc.
Accomplishments Fuel Cell Car Market Impact
Number of vehicles
deployed by 2025
Number of Miles Driven
Hydrogen Fuel Produced
Total Hydrogen Cost (
price + Subsidy)
Estimated Real Fuel Cost
Federal Subsidy
Forecourt Hydrogen
Stations Scenario
(Natural Gas Reformer)*
HHR-IFF design PEM
Electrolysis
10 million
10 million
350 billion
5.4 billion kg
350 billion
5.4 billion kg
$38B to $43B
$22B to $23B
$7 to $8 /kg
$27B
$4 to $4.25 /kg
$7B
Comparison of investment costs of forecourt infrastructure costs against home refueling. The
“at risk” investment during this transition period is nearly cut in half by the deployment of the
HHR system. This reduction in risk allows for a reduction in federal subsidy by a factor of
four.
*Analysis of the Transition to Hydrogen Fuel Cell Vehicles and the
Potential Hydrogen Energy Infrastructure Requirements, OAK RIDGE
NATIONAL LABORATORY, March 2008.
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ElectroChem Inc.
Proposed Future Work
2nd Year
1sr Year
Technology Development Plan
Q1
Q2
Q3
Q4
Q1
Q2
Q3
Q4
1. Build a High pressure electrolyzer
Usg existg Integrated Flow Field (IFF) and low
gas crossover membrane technology
2. Test the High pressure IFF electrolyzer
Internal water management
Coolg/Dryg
Temperature control/Pressure regulation
Safety control element
3. Reduce Crossover
Improve low gas crossover membrane
4. Develop Small H2 Compressor
Test with vehicle tank
Safe refuelg process
5. Design a Balance of Plant
Simpler component design
Computer microprocessor
6. Test the Balance of Plant
Safety evaluation
Installation cost study
Phase II SBIR Program
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ElectroChem Inc.